Automatic systems are one of the key variables for welding work in industrial manufacturing factories that create technological advantages that lead to increased work effectiveness. In this Metal Fab-Form article, MEGA Tech would like to present the advantages of using robots or automatic systems in your factory operations.
Weld Quality – There is a limit in welding work in creating identical work results each time, and two welders cannot produce the same weld joints that are identical in every way, and many factors such as evenness of the parts, experience, and fatigue, contribute to quality changes that might cause you to lose large amounts of time and money due to workpiece damage. In contrast, automatic systems can set movement programs with clearly-determined parameters to produce the same perfect welds each time, leading to increased consistency and higher quality.
Work Quantity and Effectiveness – An automatic system can increase work volume while working at the same speed or greater speed than manual welding. As such, the continuous operation of robots is important. Robot welders can work at a consistent speed without unscheduled break or idle times, thus leading to greater work time and greater overall production rate. Another factor is workpiece preparation. The condition of the workpiece, whether in regards to its size, clean and smooth edges, or appropriate angles, is a component for ensuring that parts are installed correctly and arranged correctly. This second factor requires collaborative work with humans for maximum effectiveness.
Development of Automatic Welding Systems – Robots are more than mere robotic arms holding welding nozzles or other components of the same nature, and these components affect system effectiveness, such as welding components, and include the following:
หุ่นยนต์อุตสาหกรรม (Industrial Robot)
ตู้คอนโทรเลอร์ (Robot Controller)
ตู้เชื่อม (Welder)
Positioner
For welding, robot arms, robot controllers, and holders help to ensure that weld lines are secure and appropriately positioned. That being said, in addition to these key components, safety devices are also important, since welding work is still dangerous, even when performed by robots. As such, sensors are accessories that detect persons or body parts to prevent robots and weld nozzles from moving in the direction where people are present in a cell or when a door is open. Features are further enhanced by the ability to verify data, and weld systems installed with software can monitor current, gas pressure, and wire used in order to prevent potential problems.
Currently, many manufacturers use robots for welding work, whether in the automotive industry, electronic industry, construction industry, or others. Most welding can be performed by mechanical arms, and this includes MIG, TIG, laser, and plasma welding, not to mention spot welding. Accordingly, what cannot be avoided during welding is spatter. Spatter is when fragments from welding cause work surfaces to be uneven or to have indentations or grains caused by welding, which will cause the work to appear to be of poor quality, thereby harming product image and standards. Welding today is a process frequently found in many types of manufacturing, especially in automotive parts manufacturing and other work that involves material attachment processes that mostly use metal, and a frequently used welding method is as follows:
In the short arc welding type MIG/MAG/CO2, spatter can easily occur due to wire delivery. Therefore, another way to reduce spatter is to use ultra-low spatter welding “EAGL”, which can reduce spatter by sending wires and pulling wires back, which reduces spatter. In addition, EAGL welding is a high-voltage welding process, so there is no need to waste time in polishing the workpiece, and no expensive gas mixed with Ar+CO2 is needed to help reduce spatter from welling, which can significantly reduce expenses and increase effectiveness. Manufacturing by the use of automated systems that implement advanced industrial technologies is something that should occur to improve production processes and reduce the gap and impacts from shortages of skilled workers. Moreover, it can be used as a weapon for enhancing manufacturing effectiveness and delivering high-precision manufacturing. Thus, as the economy of the country is developed, there is a clear trend of increasing the adoption of robots and automated systems to increase work speed and precision, as well as manufacturing effectiveness, all of which will certainly benefit factories and manufacturing industries.
Article by: Yaskawa Electric (Thailand) Co., Ltd. & MEGA Tech